Plunge base router

ABSTRACT

A plunge base router for use in an upright and an inverted position is disclosed. The router includes a depth adjustment mechanism, a depth stop mechanism, a post lock mechanism, and a return spring defeat mechanism. The depth adjustment mechanism includes a course adjustment mechanism and a fine adjustment mechanism to set the cutting distance of a bit. The course and fine adjustment mechanisms are usable in both the upright and inverted positions and the fine adjustment mechanism is operable without being reset throughout the full range of motion of the plunge router. The depth stop includes a mechanism for locking the end of a rod on the housing to the base in order to set the relative position in between the housing and the base. The depth stop also includes a plurality of steps for engaging the rod and permitting incremental passes of cutting at different depths with the router. The post lock mechanism includes a lever for locking the housing to the guide posts in a relative position relative to the base, and the lever is normally biased to the lock position. The lever includes a latch for locking the lever in the open positions so that the plunger can be easily mounted in an inverted position under a worktable without the need to hold down the lever in order to permit relative movement between the housing and the base. The return spring defeat mechanism defeats the return spring that biases the housing away from the base so that it is easier to mount the plunge router in an inverted position on the underside of a worktable.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. Ser. No. 09/627,497 filed Jul.28, 2000, now U.S. Pat. No. 6,488,455.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a plunge base router and, inparticular, to a plunge base having a number of advantageous featuresfor facilitating use of the router in either an upright position or aninverted position. The inventive features of the plunge router of thepresent invention include a depth adjustment mechanism, a depth stopmechanism, a post-lock mechanism, and a return spring defeat mechanism.

2. Scope of the Prior Art

Plunge base routers have long been used to make grooves and cuts ofvarious types. Such routers include a housing having a motor whichrotates a router bit for making grooves and cuts in a work. The housingis vertically movable relative a base on two guide posts that areconnected to the base. It is known that a plunge base router can be usedin an upright (or normal position) and an inverted position for useunder a router table. In the upright position, the router can plunge onthe posts and is used to make cutouts, for grooving and edge-forming ofwood or other solid-surface materials. When the router is mounted underthe table, it is used like a shaper mainly for cutting repetitive shapesand for heavy decorative edge-cuts. When used in the upright position,the term cutting depth is used to describe the amount that the bit isexposed through the base. When used in the inverted position, the termcutting height describes the amount that the bit is exposed above therouter table.

Typically, the housing of the plunge base router is slidable on theguide posts to permit plunging of the router and positioning of thehousing relative to the base. The housing contains a compression springadjacent to at least one of the guide posts for biasing the housing awayfrom the base. The compression spring may be on the outside or inside ofthe post.

Most plunge base routers provide a depth adjustment mechanism toaccurately position the bit at the correct cutting depth or height. Somerouters provide a course adjustment mechanism to generally find thedepth or height and a fine adjustment mechanism to accurately locate thedepth or height. The course and fine adjustment mechanisms are both usedto arrange the router for the desired cutting depth or height.

The prior art plunge base routers typically include a fine adjustmentmechanism that is separate from the course adjustment mechanism. In suchmechanisms, the fine adjustment mechanism typically has a short range oftravel for fine tuning the adjustment of the course adjustmentmechanism. Thus, if it is determined after making a cut that a largeradjustment is needed, both the course adjustment mechanism and the fineadjustment mechanism must be reset. The process of resetting both thecourse and fine adjustment mechanisms is fairly time consuming becauseboth adjustment mechanisms must be zeroed again and the cutting depth orheight completely reset. It is therefore believed to be desirable tohave a plunge base router where the course and fine adjustmentmechanisms are interdependent so that they do not have to be reset andzeroed repetitively.

A number of prior art plunge base routers are shown in issued U.S.patents. For example, U.S. Pat. No. 4,770,573 to Monobe et al. disclosesa plunge base router that uses a bolt and nut mechanism for courseadjustment. The nut mechanism moves between a released position so thatthe plunge base router can be adjusted and a locked position to hold thebolt. The upper end of the bolt includes a knob for fine adjustment ofthe router. U.S. Pat. No. 4,938,264 to Ferenczffy discloses a clampingscrew for use as a course adjustment mechanism. U.S. Pat. No. 5,191,921to McCurry discloses a pinion and gear arrangement as a courseadjustment mechanism. However, in each of these constructions, the fineadjustment mechanism has a limited travel length, and both the courseand fine adjustment mechanisms may need to be reset and zeroedrepetitively in order to arrive at the final cutting depth or height.

In prior art constructions, it can be difficult to adjust the cuttingheight of the plunge base router when the router is in an invertedposition due to the weight of the router. The operator often finds itawkward to reach under a router table to press up on the router whenadjusting the cutting height. It is therefore believed to be desirableto have a plunge base router that assists the operator with supportingthe weight of the router during adjustment of the router in the invertedposition.

After a final cutting height or depth is established, most plunge baserouters include a post lock lever for locking the router in a selectedposition. The post lock lever is normally biased to the locked position,and the user must press on the post lock lever to release a lockingmechanism so that the housing can be moved relative to the base.However, pressing the post lock lever when the router is in the invertedposition and mounted under a router table can be awkward and difficult.It is therefore believed to be desirable to incorporate a mechanism forholding the post lock lever in the released position for easieradjustment of the router.

Plunge base routers typically have a compression spring that biases thehousing away from the base and this compression spring can make it moredifficult to mount the plunge base router in the inverted position undera router table. In particular, when an operator is mounting the routerin the inverted position under a router table, the operator must holdthe substantial weight of the router as well as push against the forceof the compression spring in order to mount the router in the invertedposition. Effectively, the compression spring adds to the weight of therouter when an operator mounts it for inverted use. It is thereforebelieved to be desirable to provide a mechanism for defeating the forceof the compression spring when the router is to be used in the invertedposition.

SUMMARY OF THE INVENTION

The plunge base router of the present invention is particularly suitedfor use in either an upright position or an inverted position under arouter table. The router includes several advantageous features tofacilitate such use, and includes an advantageous mechanism foradjusting the cutting depth or height of the router. The router includesa base, a motor to rotate a bit, and a housing encasing the motor andbeing movable relative to the base on at least one guide post foradjustment of a cutting depth or height of the bit. The router furtherincludes a return spring for providing a spring force between the baseand the housing and biasing the housing away from the base.

In an embodiment, the router includes a means for defeating the springforce of the return spring on the router. The return spring defeat meansis particularly advantageous for using the router in an invertedposition because the operator does not need to struggle against both theweight of the router and the force of the return spring when mountingthe router under a router table.

In an embodiment, the return spring defeat means includes a spring rodmounted within the return spring and having a first end engaging thereturn spring and second end having a groove and a head. A spring clipis movably mounted in the base and is movable between a first positionnot engaged with the spring rod and a second position engaged in thegroove in the spring rod to vertically lock the spring rod and to defeatthe return spring. When the spring rod is vertically locked, the firstend of the spring rod that engages the return spring holds the returnspring in a compressed condition or state so that its spring force isdefeated. The base further includes a button that engages the springclip and is adapted to selectively move the spring clip between thefirst position in which it does not engage the spring rod and the secondposition in which it engages the spring rod and defeats the returnspring.

In an embodiment, the first or top end of the spring rod includes a snapring that engages the top of the return spring, and when the spring cliplocks the spring rod, the snap ring holds the return spring in thecompressed state or condition.

In an embodiment, the spring clip includes first, second and third legsthat form a triangle. The first leg extends under the button and biasesthe button toward the upward position. The second leg includes a freeend that rides along the side of the button. The button includes a topportion that can be depressed by the operator, a small diametermid-portion, and a large diameter bottom portion. In use, the button isdepressed so that the free end of the spring clip moves into the smallerdiameter mid-portion and the free end also engages the groove in thespring rod to vertically lock it in position. The button can then bedepressed again so that the free end of the spring clip is movedadjacent to the larger diameter portion and the spring clip is movedaway from the spring rod so that it does not lock it in position.

In an embodiment, the plunge base router of the present inventionincludes both a course adjustment and a fine adjustment mechanism. Theadjustment mechanisms include a rod vertically mounted on the housingand being axially movable relative to the housing to set a cutting depthof the router. The rod preferably takes the form of a worm rod having athreaded portion. A course adjustment knob is connected to a gearmounted within the housing and the gear engages the threaded portion ofthe worm rod. The course adjustment knob and gear are rotatable to causeaxial movement of the rod relative to the housing. A gear lock lever isalso provided for locking the course adjustment knob and gear in aselected position. When the course adjustment knob and gear are lockedin a selected position, the gear acts as a nut against which the wormrod can travel.

The depth adjustment mechanism further includes a fine adjustment knobsecured to the rod for rotating the rod around its longitudinal axis.The fine adjustment knob and rod are rotatable, when the gear leverlocks the gear in the selected position, to cause axial movement of therod relative to the housing.

In use, the course and fine adjustment mechanism are used to adjust theposition of the rod relative to the housing so that a free end of therod is positioned a selected distance away from a surface on the base ofthe router. When the router is plunged, the free end of the rod hits thesurface on the base and sets the cutting height or depth of the router.

In an embodiment, the router includes a rotatable depth stop mounted onthe base under the worm rod. The rotatable depth lock includes a surfacefor engaging the rod and fixing the relative position of the housingwith respect to the base to set the cutting depth or height of therouter.

In an embodiment, the rotatable depth lock also includes a protrusionadapted for engaging a groove on the free end of the rod and locking therod to the base. The depth lock is rotatable between a first position inwhich the protrusion engages the groove on the free end of the rod andlocks the rod to the base, and a second position in which the protrusiondoes not engage the groove in order to allow axial movement of the rod.The rotatable depth lock is advantageously used to lock the rod to thebase when it is desired to use the plunge base router in an invertedposition. In the inverted position, the rod that is fixed to both thehousing and the base help support the weight of the housing and motor,which makes it easier for the operator to adjust the cutting height ordepth of the router.

In an embodiment, the depth stop includes a keyhole having a firstopening large enough to receive the head and groove of the worm rod, anda second opening smaller than the head of the worm rod and being definedby the protrusion that engages the groove of the rod to lock the rod tothe base. In use, the head of the rod are inserted into the firstopening, and then the rotatable depth stop is rotated so that theprotrusion of the second opening engages the groove and locks the rod tothe base.

The rotatable depth stop may also include a recess on its underside fortrapping the head on the rod. This prevents the rod from becomingdislodged for the rotatable depth stop during use of the router.

In an embodiment, the plunge base router includes a post lock lever anda means for holding the post lock lever in the released position. Thepost lock lever includes a lock element movable between a lockedposition wherein the housing is fixed relative to the base and areleased position wherein the housing is movable relative to the base. Atorsion spring biases the post lock lever and lock element into the lockposition. A latch is provided that is movable to secure the post locklever and lock element in the released position when desired. The latchis particularly useful for holding the post lock lever in the releasedposition when it is desired to mount the router in an inverted positionunder a router table.

In an embodiment, the latch is mounted on the post lock lever, and a pinpivotally secures the latch to the lever. The latch includes a distalend that can project outwardly from the lever to engage a boss on thehousing and hold the post lock lever in the released position. A secondspring may be provided for biasing one end of the latch outward, andthat end of the latch can then be depressed so that the latch pivots andthe distal end engages the boss on the housing. The latch isparticularly advantageous for defeating the post lock lever and holdingit in the released position when it is desired to use the plunge baserouter in the inverted position under a router table.

These and numerous other features and advantages of the presentinvention will become readily apparent from the following description,the accompanying drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a plunge base router made in accordance with theprinciples of the present invention;

FIG. 2 shows a top view of the plunge base router with a partialcut-away portion in the vicinity of the course adjustment mechanism;

FIG. 3 is a cross-sectional view of the router taken along the line 3—3in FIG. 1;

FIG. 4 is a perspective view of the course adjustment mechanism, fineadjustment mechanism and return spring defeat mechanism of the presentinvention;

FIG. 5 illustrates operation of the fine adjustment mechanism;

FIG. 6 illustrates a further view for the operation of the fineadjustment mechanism;

FIG. 7 illustrates operation of the course adjustment mechanism;

FIG. 8 illustrates a further view for the operation of the courseadjustment mechanism;

FIG. 9 is a partial cut-away view of the depth stop used as a part ofthe present invention

FIG. 10 is a view of the depth stop shown in FIG. 9 where the worm rodis inserted into the keyhole;

FIG. 11 illustrates the post lock mechanism of the present inventionshown in one position;

FIG. 12 illustrates the post lock mechanism of FIG. 11 in a secondposition;

FIG. 13 illustrates the post lock mechanism in yet another position;

FIG. 14 illustrates a partial bottom view of the plunge base routershowing the return spring defeat mechanism of the present invention;

FIG. 15 shows the return spring defeat mechanism where the rod is beingplunged and the spring clip is in its outward position;

FIG. 16 shows the return spring defeat mechanism where the rod is in itslowest position;

FIG. 17 shows the return spring defeat mechanism where the smallestdiameter of the button is aligned with the spring clip;

FIG. 18 shows the return spring defeat mechanism where the return springpressure is defeated by the mechanism;

FIG. 19 shows the return spring defeat mechanism released to allow thereturn spring to exert pressure;

FIG. 20 shows a cross-sectional view of the post lock mechanism in oneposition; and

FIG. 21 shows a cross-sectional view of the post lock mechanism in asecond position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 1-3, the numeral 10 designates a plunge base router10 including a motor (not shown) that rotates a router bit (not shown).A shaft lock assembly 20 is connected to the motor to hold and rotatethe bit. The motor is encased by a housing 22, which includes a mainhousing 24, a fan housing 26 and a cover 28. The router 10 also includesa base 30 that has at least two guide posts 32 attached to it. The posts32 extend perpendicularly from the upper surface 34 of the base 30 andextend into holes (not shown) formed in the housing 22. The housing 22is movable in a longitudinal direction along the posts 32 relative tothe base 30 and bushings 36 (FIG. 3) assist in the movement of thehousing 22 along the guide posts 32. Bellows 37 are provided between thebottom of the housing 22 and the upper surface 34 of the base 30 toprotect the guide posts 32 from the debris and dust created by use ofthe router 10.

Depth Adjustment Mechanism

Referring to FIGS. 1 and 4-8, the numeral 12 generally designates adepth adjustment mechanism to position the router bit with respect tothe base 30. As best shown in FIGS. 4-8, the depth adjustment mechanism12 includes a course adjustment mechanism 50 and a fine adjustmentmechanism 52. The user operates mechanisms 50 and 52 to set the cuttingdepth or height of the router bit.

The course adjustment mechanism 50 includes a worm rod 54 that has anupper end 56 and a lower end 58. The worm rod 54 includes a threadedportion 60 between the ends 56 and 58. At the upper end 56, the worm rod54 also includes a flat section 62 that forms a generally D-shapedcross-section. A groove 63 extends around the circumference of the lowerend 58 of the rod 54 to form a cap 64.

An elongated sleeve 66 having a longitudinal slot 68 surrounds the rod54 so that the threaded portion 60 adjacent the housing 22 is exposed bythe slot 68. The sleeve 66 fits into a hole with a key (not shown)provided in the housing and will not turn when the worm rod 54 isrotated. The sleeve 66 is shorter than the worm rod 54 so that the upperend 56 and the lower end 58 of worm rod 54 extend out of the ends of thesleeve 66. The sleeve 66 protects the threaded portion 60 on the rod 54from the debris and dust created by the router 10. The sleeve 66 alsogrips the threaded portion 60 to resist rotation of rod 54 due tovibration during use of the router.

The course adjustment mechanism 50 also includes a gear 72 having gearteeth 74 engaged with the threaded portion 60 of worm rod 54. The gear72 is mounted on one end of gear shaft 76, and the opposing end of gearshaft 76 includes a flat section 78 having a generally D-shapedcross-section. A course adjustment knob 114 is fitted onto the generallyD-shaped end 78 of shaft 76, and rotation of knob 114 causes gear 74 toengage and travel along the threaded portion 60 on shaft 54.

As shown most clearly in FIGS. 2 and 3, the shaft 76 and gear 74 arefixed within housing 22 of router 10. Accordingly, rotation of knob 114and gear 74 causes relative movement between the housing 22 and rod 54.

The course adjustment mechanism 50 is provided with a lock assembly 80(FIG. 4) that may be operated to prevent the gear 74 from rotating. Theassembly 80 includes a gear lock screw 82, a nut 84 and a lever 86. Thegear lock screw 82 has a hexagonal-head end 88 and a threaded end 90. Ina preferred embodiment, the threads on the threaded end 90 areleft-handed. The screw 82 also has a center hole 92 extendinglongitudinally along its axis between head end 88 and threaded end 90. Acircumferential flange 94 is positioned between the head end 88 and thethreaded end 90 creating a groove 96 between the head end 88 and theflange 94.

The nut 84 of lock assembly 80 has a threaded center hole 98 whichthreads onto the threaded end 90 of the gear lock screw 82. The lever 86of lock assembly 80 includes a circular portion 100 and a lever 102. Thecircular portion 100 defines a hexagonal hole 104 that surrounds andengages the hexagonal-head end 88 of the gear screw 82.

As assembled, the gear shaft 76 fits through the longitudinal hole 92 ofthe gear lock screw 82 such that the flat section 78 extends out of theassembly. An indicator ring 106 having a center hole 108 slides over theend of the gear shaft 76. The knob 114 is then connected to the flatsection 78 of shaft 76, and screw 116 secures the knob 114 and indicatorring 106 on the gear shaft 76. In a known manner, the indicator ring 106is rotatably connected to the knob 114 to zero the course adjustmentmechanism 50. The indicator ring 106 can be rotated independently fromthe knob 114, but rotation of knob 114 causes rotation of the indicatorring 106.

FIGS. 2 and 3 most clearly illustrate the positioning of the courseadjustment mechanism 50 within housing 22. The housing 22 defines a hole118 and a cavity 120, and the hole 118 is preferably in the fan housing26. The gear shaft 76 and gear lock screw 82 extend through the hole 118in the fan housing 26. The fan housing 26 fits within the groove 96between the hexagonal end 88 and the flange 94 of the gear lock screw82. A washer 122 can be used between the gear lock screw 82 and thehousing 22 to prevent galling between the housing 26 and the screw 82.The gear 72, the threaded end 90 of the gear lock screw 82 and the nut84 are disposed within the cavity 120 of the housing. In contrast, thelever portion 86, the head end 88 of the gear lock screw 82, theindicator ring 106 and the knob 114 are disposed outside the housing 22.

Referring to FIGS. 2 and 4, a spring 124 is connected to an outer edgeof the nut 84 and biases the nut 84 and gear 72 towards the worm rod 54.Thus, the spring 124 takes up the backlash and play between the gear 72and the worm rod 54. When the lever 22 is rotated clockwise, the gearlock screw 82 presses the nut 84 against the gear 72 and locks gear 72against housing 26. In a preferred embodiment, the outer face of thegear 72 is waffled (not shown) to help lock the gear 72 against thehousing 26 and to prevent rotation. Once the gear 72 is locked in place,the gear 72, and the gear teeth 74, act like a nut for the worm rod 54and teeth 60.

Referring to FIGS. 4-8, the fine adjustment mechanism 52 is connected tothe upper end 56 of the worm rod 58. The fine adjustment mechanism 52includes a indicator ring 126 having a center hole 128 fitted over theworm rod 54 and having a scale 130 with multiple indicator marks 132. Afine adjustment knob 134 is connected to the flat section 62 of the wormrod 54. In a known manner, the knob 134 and indicator 126 are arrangedso that the indicator ring 126 can rotate independently of the knob 134,but rotation of knob 134 causes rotation of indicator ring 126.

When rotated, the knob 134 rotates the worm rod 54, and indicator ring126 having the scale 130 with multiple indicator marks 132 on indicatorring 126 is used to zero the fine adjustment knob 134 and to provide abenchmark for fine adjustment of the cutting depth or height of therouter 10. The sleeve 66 includes an indicator mark 70 which is used asa reference for the fine adjustment mechanism 52.

The fine adjustment mechanism 52 is used after the course adjustmentmechanism 50 is adjusted and in the locked position with gear 72 lockedagainst housing 26. In that position, the gear 72 acts as a nut, androtation of fine adjustment knob 134 and worm rod 54 causes relativemovement between the worm rod 54 and the housing 22.

When the router 10 is used in the upright position, the housing 22 isplungable on guide rods 32 to the desired cutting depth. As shown mostclearly in FIG. 1, the worm rod 54 has its second free end 58 projectingdownwardly from housing 22 and above a surface (depth stop 40 describedin more detail below) on base 30. The housing 22 is plunged with respectto the base 30, and the worm rod 54 and its second free end 58 contactthe surface on the base to stop the plunging action at the correct depthwhich is set by the relative position between worm rod 54 and thehousing 22.

In order to adjust the relative position between worm rod 54 and housing22, the user first turns the course adjustment knob 114 and gear 72 tocause relative movement between the housing 22 and worm rod 54.Thereafter, the user turns lever 102 to lock gear 72 against the housing26. The fine adjustment knob 134 can then be turned to rotate worm rod54 and fine tune the relative positioning of worm rod 54 with respect tothe housing 22.

The above described course adjustment mechanism 50 and fine adjustmentmechanism 52 are particularly advantageous because the fine adjustmentmechanism 52 is operable at almost any point along the entire range ofmovement of the housing 22 with respect to the worm rod 54. Accordingly,in order to fine tune the cutting depth or height, the operator can usejust the fine adjustment mechanism 52 to accomplish that goal withoutthe need to reset and zero both the course adjustment and fineadjustment mechanisms for each adjustment, which is common in prior artplunge base routers.

Depth Stop

Referring to FIG. 1, the depth stop 40 forms a surface on base 30 forengaging the second free end 58 of worm rod 54, when the router isplunged, in order to set the cutting depth or height of the router 10.The depth stop 40 is used in this manner, mostly for use in the uprightor normal position of the router 10. Advantageously, the depth stop 40of the present invention can also be used to secure the base 30 to thefree end 58 of worm rod 54 for providing an alternate mechanism foradjusting the cutting depth or height of the router 10. This mechanismis particularly advantageously for use of the router 10 in the invertedposition.

As shown most clearly in FIGS. 9 and 10, the depth stop 40 is agenerally circular piece that has an upper end 150 and a lower end 152and is rotationally connected to the base in a known manner. The upperend 150 of depth stop 40 has a turret assembly 154 with multiple steps156, for positioning under the worm rod 54 in a known manner for settingthe cutting height or depth.

The depth stop 40 of the present invention further includes a keyhole158 having a first larger diameter section 160 and a second smallerdiameter section 162. The first section 160 is large enough for thelower end 58 of the worm rod 54 to be inserted into the depth stop 40.The second section 162 is approximately the same as, or slightly largerthan, the diameter of the groove 63 under cap 64 on the worm rod 54. Inorder to lock the worm rod 54 to depth stop 40, the worm rod 54 is firstinserted into the first section 160 of the depth stop 40, and then thedepth stop 40 is rotated so that the groove 63 on worm rod 54 isinserted into the second section 162 of depth stop 40. The wall of thedepth stop 40 that defines the second section 162 acts as a projectionto engage groove 63 on the worm rod 54 and to lock the worm rod 54 tothe depth stop 40.

As shown most clearly in FIGS. 9 and 10, the depth stop 40 also includesan indent 164 on the lower end 152 in the vicinity of the second section162. The indent 164 receives the cap 64 on worm rod 54, and provides alip 166 to secure the worm rod 54 in the second section 162. Thisminimizes the tendency of the depth stop 40 to rotate when the worm rod54 is in the second section 162 and prevents the worm rod 54 from beingdislodged from the depth stop 40.

When the router 10 is in an upright position, as seen in FIGS. 5-8, thedepth stop 40 acts as a contact surface on base 30 for engaging worm rod54 and stopping relative movement between the housing 22 and base 30. Inuse, the operator first positions the end of the router bit against thematerial to be cut. The post lock mechanism 14 (discussed below) is thenlocked. The worm rod 54 is then positioned against the top of the depthstop 40. The course adjustment mechanism 50 and the fine adjustmentmechanism 52 are then zeroed by rotating the indicator rings 106 and126, respectively. The course adjustment knob 114 is then put into areleased position and rotated to find the approximate cutting depth. Theknob 114 is used to set a distance between the bottom of the worm rod 54and the top of the depth stop 40, which is the general cutting distance.The lever 102 is then rotated to lock the gear 72 and the courseadjustment mechanism. The fine adjustment knob 134 is then rotated sothat worm gear 54 travels upward or downward against fixed gear 72 tofine tune the adjustment of the cutting depth. The fine adjustment knob134 can be used to rotate and adjust the worm rod 54 along its completethreaded length 60 to permit a wide range of adjustment with the fineadjustment mechanism.

After final adjustment of the cutting depth, the post lock levermechanism 14 is released and the housing 22 will travel to its furthestpoint away from the base 30. The router 10 can be plunged downward sothat the bottom end 58 of worm rod 54 hits the depth stop 40 at thecorrect cutting distance within a work. The depth stop 40 can also berotated to align a selected one of the multiple steps 156 with thebottom end 58 of worm rod 54 in order to make a number of incrementalcuts in the work before achieving the final cutting depth. The depthstop 40 has a spring loaded detent mechanism (not shown) for holding thedepth stop 40 in different rotational positions.

When the router 10 is used in the inverted position, the operator mayadvantageously lock the worm rod 54 in the keyhole 158 in the depth stop40. In particular, the cap 64 on worm rod 54 is inserted into the largerfirst opening or section 160, and the depth 40 is then rotated so thatthe groove 63 under cap 64 is locked in the smaller second opening orsection 162 in depth stop 40. When the router 10 is then placed in theinverted position, the worm rod 54 will help hold the weight of therouter housing 22 to alleviate some of the need for the operator tosupport the weight of the housing 22 and the motor when adjusting thecutting height.

In order to adjust the cutting height in such an inverted position, theoperator rotates the course adjustment knob 114 so that gear 72 isrotated and travels along the worm rod 54. This pulls the housing 22along with the gear 72 to a desired rough cutting depth. The lever 102is then rotated to lock the gear 72 in position, and the fine adjustmentknob 134 is used to rotate worm rod 54 for precisely adjusting thecutting depth. When the fine adjustments are made, rotation of the fineadjustment knob 134 forces gear 72 to act like a nut and travel up ordown worm gear 54 along with the housing 22 to a selected positionrelative the base 30. As described in more detail below, the post lockmechanism 14 is preferably released during inverted operation, and acompression spring defeat mechanism is also preferably used in theinverted position to defeat the compression spring.

Post Lock Mechanism

The post lock mechanism 14 of the present invention is shown in FIGS. 1,11-13 and 20-21. The post lock mechanism 14 secures the housing 22 in aposition relative to the base 30 by engaging one of the guide posts 32.The mechanism 14 includes screw 172 having a first end 170 movablyengagable with one of the guide posts 32. Preferably, the screw 172 ismade of brass and the guide post 32 is made of steel.

The screw 172 has a second end 174 secured to a lever 176 having firstand second ends 178 and 180. The first end 178 has a hole 179 into whichend 174 of screw 172 fits so that the lever 176 rotates the screw 172.End 180 of the lever extends out from the housing 22 for actuation by auser. The user pushes end 180 of lever 176 to rotate screw 172 so thatit is fixed tightly against post 32 as shown in FIG. 11 to fix therelative position of the house 22 to the base 30. As shown in FIG. 12,the user pushes on end 180 of lever 176 to rotate the screw 172 in theopposite direction to draw the screw 172 away from shaft 32 in order torelease the housing 22 relative to the glide post 32 and base 30.

The post lock mechanism 14 further includes a torsion spring 182 (FIGS.2 and 20) that biases lever 176 and shaft 172 to the locked positionagainst post 32 to secure the relative position of the housing 22 tobase 30. In use, the lever 176 and shaft 172 keep the housing 22 fixedrelative to base 30, and the operator uses lever 176 to defeat the postlock mechanism to permit movement of the housing 22 relative to the base30 on guide post 32. Thus, the post lock lever mechanism 14 is normallyin the locked position, and the lever 176 is actuated to release housing22 for movement on guide post 32.

The post lock mechanism 14 also includes a latch 184 for holding thepost lock lever 176 in the open position against the force of torsionspring 182. The latch 184 is mounted in an opening 188 on lever 176, anda pin 194 pivotally connects a mid-portion 190 of latch 184 to the lever176. A spring 195 is positioned between a first end 186 of latch 184 andthe lever 176 for biasing the first end 186 of latch 184 outward. Asshown in FIG. 20, the spring 195 biases the latch 184 to pivot about pin194 so that the distal end 196 of latch 184 is pressed tight againstlever 176 and is generally flush with projection 197 at the end of lever176. In such a position, the lever 176 can be rotated without latch 184engaging a boss 198 on the housing 22 of router 10. When a user pressesdown on a first end 186 of latch 184, the distal end 196 of lever 184projects outwardly from lever 176 and projection 197 so that it canengage the boss 198 as shown in FIG. 21. When the latch 184 engages theboss 198, the lever 176 is locked in the open or released position sothat shaft 172 is not locked against post 32 and the housing 22 can bemoved relative to the post 32 and base 30.

In operation, the torsion spring 182 biases the lever 176 and screw 172into the engaged or locked position against the guide post 32. Thehousing 22 is therefore held in a secured position relative to the base30. To move the housing 22 relative to the base, the post lock levermechanism 14 must be moved from the locked position into a releasedposition. To do so, lever 176 is moved by the user to overcome the biasof torsion spring 182 and to rotate the screw 172 from an engagedposition to a released position away from the guide post 32. When theuser holds the lever 176 in this position, the user is free to move thehousing 22 relative to base 30 and into a desired position.

In some circumstances, such as for inverted use of the router 10, it isdesirable to defeat the lock lever mechanism and secure lever 176 in theopen or released position. For such use, the user presses down on thefirst end 186 of latch 184 so that the opposite distal end 196 projectsoutward and engages boss 198 on the housing 22, which holds the lever176 in the open or released position. The housing 22 is then free tomove along the guide post 32 and relative to the base 30. To release thelatch from the boss 198 on housing 22, the latch 184 is once againdepressed so that the latch is removed from the boss 198. The torsionspring 182 then returns the lever 176 and the screw 172 to be engagedposition against the guide post 32 to hold the housing 32 in a fixedposition.

Compression Spring Defeat Mechanism

Referring to FIG. 3, a return spring 42 is provided on one of the guidepost 32 and provides a spring force between the base 30 and housing 22that biases the housing 22 away from the base 30. When it is desired touse the router 10 in the inverted position, the operator must overcomeboth the weight of the router 10 and the force of the return spring 42to collapse the plunge router 10 under the work table. Typically, thecombined weight of the router 10 and force of the motor return spring 42have made it an exceededly difficult task for positioning the router 10under a table and for adjusting the cutting height.

In order to overcome the above mentioned problems, the present inventionadvantageously incorporates a return spring defeat mechanism generallydesignated with the numeral 16 in FIGS. 3-4 and 14-19. As shown, thereturn spring 42 surrounds a spring rod 202 positioned within the guidepost 32. The upper end 204 of the spring rod 202 includes a snap ring206 that holds the spring 42 on the spring rod 202. The lower end 210 ofthe spring rod 202 includes a groove 212 under a head 214. Normally, thespring rod 202 travels with the movements of the housing 22 due to theengagement of top wall 208 of the housing 22 with the top end 204 of thespring rod 202 and the snap ring 206 that engages the spring 42.

The router 10 of the present invention advantageously includes means fordefeating the force of the return spring 42. In the embodiment given inthe drawings, the spring defeat mechanism includes a clip meanspositioned in the base 30. The clip means includes a generallytriangular shaped spring clip 216, a button 218 and a cover plate 220(FIG. 14). The spring clip 216 includes a circular portion 222 that fitsover the pin 224 to position the spring clip 216 in the base 30. Thespring clip 216 also includes two free ends 226 and 228 that meet at onepoint of the triangular shape. Free end 226 engages with the underside230 of button 218, and free end 228 engages with the upper portion ofbutton 218. The cover plate 220 is connected to the base 30 by a screw234 and holds the spring clip 216 so that the free end 226 biases thebutton 218 toward an upper position.

The button 218 includes a large diameter section 236 at the bottom, asmall diameter section 238 in its middle, and an upper portion 240 whichextends through the base 30 and above the upper surface 34. The upperportion 240 can be depressed by the user. The free end 228 of the springclip 216 can engage with either the large diameter section 236 or asmall diameter section 238 of the button 218 as shown in FIGS. 15-19.When engaged with the small diameter section 238, the spring clip 216 isin an inward position (FIGS. 18 and 19). When engaged with the largediameter section 236, the spring clip 216 is in an outward position(FIGS. 15-16). The spring clip 216 is mounted within the housing 22 sothat its free end 228 is biased towards the inward position and isvertically trapped by the base 30 and cover plate 220. As shown in FIGS.18 and 19, when the free end 228 engages the small diameter portion 238of button 218 in the inward position, the free end 228 can also engagethe groove 212 above head 214 in spring rod 202.

The operation of the return spring defeat mechanism 16 is shown in FIGS.15-19. In FIG. 15, the user plunges the router 10 and therefore thehousing 22 against the compression return spring 42. As the housing 22moves, the rod 202 moves and the lower end 210 passes the spring clip216 as shown in FIG. 16. In this position, the spring clip 216 is heldin the outward position by the large diameter section 236 of the button218 and does not engage rod 202. To defeat the return spring 42, theuser depresses the button 218 and holds it down, as seen in FIG. 17. Inthis position, the free end 228 of the clip 216 moves from the largeportion 236 of the button 218 to the small portion of the button 218. InFIG. 18, the user allows the spring rod 202 to move up slightly, and thespring clip 216 moves into groove 212 on rod 202. The spring clip 216thus locks rod 202 in place. The user then releases the button 218 andthe return spring 42 is defeated because the snap ring 206 on rod 202holds the spring 42 in a compressed state. Once the return spring 42 isdefeated, the user will find it much easier to position the router 10 inan inverted position under a work table.

In FIG. 19, the router 10 is shown being restored into its normaloperation. In particular, the user pushes the housing 22 all the waydown again which causes the rod 202 to move slightly downward. Thetapered upper end of the groove 212 pushes the spring clip 216 and freeend 228 outward. This allows the button 218 to automatically pop up fromthe spring pressure exerted by free end 226 and cover plate 220. Whenthe button 218 is in its upward position, the large diameter section 236is again holding the free end 228 in its outward position and thecompression spring 42 is no longer defeated.

Although the present invention has been described in considerable detailwith reference to certain preferred versions, other versions arepossible. Therefore, the spirit and scope of the appended claims shouldnot be limited to the description of the preferred embodiment described.

What is claimed is:
 1. A plunge base router having a motor to rotate abit, the router comprised of: a base; a housing encasing the motor andmovable relative to the base on at least one guide post; a post locklever mounted on the housing adjacent to a boss formed on the housing,the post lock lever having a lock element moveable between a lockedposition wherein the housing is fixed relative to the base and areleased position wherein the housing is movable relative to the base; aspring biasing the post lock lever and lock element to the lockedposition wherein the housing is fixed relative to the base; and a latchmoveable to engage the boss and secure the post lock lever and lockelement in the released position wherein the housing is movable relativeto the base.
 2. A plunge base router having a motor to rotate a bit, therouter comprised of: a base; a housing encasing the motor and movablerelative to the base on at least one guide post; a post lock leverhaving a lock element moveable between a locked position wherein thehousing is fixed relative to the base and a released position whereinthe housing is movable relative to the base; a spring biasing the postlock lever and lock element to the locked position wherein the housingis fixed relative to the base; and a latch mounted on the post locklever, the latch moveable to secure the post lock lever and lock elementin the released position wherein the housing is movable relative to thebase.
 3. The router of claim 2 in which the lever includes an end havinga projection, and the latch includes a distal end that is flush with theprojection when the latch does not engage the boss.
 4. The router ofclaim 2 wherein the latch is mounted in an opening on the post locklever.
 5. The router of claim 2 wherein a pin pivotally secures thelatch to the post lock lever.
 6. A plunge base router having a motor torotate a bit, the router comprised of: a base; a housing encasing themotor and movable relative to the base on at least one guide post; apost lock lever having a lock element moveable between a locked positionwherein the housing is fixed relative to the base and a releasedposition wherein the housing is movable relative to the base, the leverincluding an end having a projection; a first spring biasing the postlock lever and lock element to the locked position wherein the housingis fixed relative to the base; a latch including a distal end that isflush with the projection when the latch does not engage the boss, thelatch mounted on the post lock lever and moveable to secure the postlock lever and lock element in the released position wherein the housingis movable relative to the base; and a second spring interposed betweenthe latch and the lever.
 7. The router of claim 6 in which the first endof the latch is depressible to pivot the latch about the pin and causesthe distal end of the latch to project beyond the protrusion on thelever in order to engage the boss on the housing.
 8. The router of claim6 wherein: the second spring is interposed between an end of the latchopposite the distal end and the lever; and the second spring biases thelatch to the position wherein the distal end is flush with theprotrusion on the lever.
 9. A plunge base router for use in an uprightposition and an inverted position, the router comprising: a base; amotor to rotate a router bit; a housing encasing the motor; at least oneguide post connected to the base, the housing being movable relative tothe base on at least one guide post; and a post lock lever movablebetween a locked position to secure the housing in a position relativeto the base and an open position so that the housing is movable relativeto the base, a torsion spring biasing the lever to the locked position,and a latch movably mounted on the lever and being movable to engage aboss formed on the housing and to hold the lever in the open position.10. The router of claim 9 further comprising a second spring to bias thelatch into a position wherein the latch does not engage the boss. 11.The router of claim 9 wherein the latch pivots on a pin connected to thelever.